Adaptive manufacturing system

ABSTRACT

A system and method for processing a flexible part comprising holding the flexible part securely in an unconstrained position using a holder; and controlling a positioner to process the flexible part based on a comparison of a shape and/or position of the flexible part in the unconstrained position with design specifications of the part not in the unconstrained position.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation and claims priority to U.S. patentapplication Ser. No. 14/717,742, filed May 20, 2015; which claims thebenefit of U.S. Provisional Patent Application Ser. No. 62/000,635,filed May 20, 2014, the contents of both are also incorporated herein byreference in their entirety.

BACKGROUND

The manufacturing or processing of flexible workpieces (herein referredto also as “parts”) is often a difficult task. A flexible part is anon-rigid body that has a portion, portions or the entire body of thepart that deforms due to a relatively light force, such as but notlimited to the force of gravity, applied thereto. Often the flexiblepart is made from a flexible material and/or the material is thin, whichprevents the flexible part from retaining a solid rigid body. Forinstance, flexible parts made from a molding process can change shape,at least partially, when the parts are removed from the mold. In otherwords, the flexible part often does not retain the exact shape of themold, but rather, takes a different shape when unconstrained by themold.

By way of example, FIG. 1 illustrates an exemplary 3-dimensional portionof a flexible part 10 that includes a U-shaped center section 12 andopposed flange portions 14. Being formed of a relatively thin orlightweight material, the width of the U-shaped center section 12 canvary along its length. In this exemplary part, variance can particularlyexist where a top portion of the center section 12 joins to the sideportions, as represented by double arrow 16. Likewise, the angle atwhich the flange 14 extends from the center section represented bydouble arrow 24 can vary or can change along its length. These variancesare merely illustrative in that an actual flexible part can experiencevariances in any or all degrees of freedom.

Although the part 10 is flexible, such flexible parts are often mountedor secured to another body (not shown) whereupon when mounted, theflexible part 10 and the body together may yield a substantially rigid,or at least less flexible overall structure. However, before theflexible part 10 can be secured to the body, often the flexible part 10must be processed so as to have a specific shape of features, whichwithout limitation, can include recesses 17, by way of example,apertures, cut outs, desired thickness at selected portions of theflexible part, etc. all pursuant to exact specifications. Suchprocessing can include but is not limited to drilling, milling,trimming, scribing, chamfering and using any manufacturing techniquesuch as but not limited to machining, waterjet cutting, laser or plasmacutting, etc. In addition, processing of the flexible part 10 can alsoinclude inspecting the flexible part 10 to see if the flexible part 10meets the desired specifications. Inspection can include use of any formof inspection or measuring device such as but not limited toprofilometers, offset lasers, probes and cameras to list just a few.

Commonly, known techniques for processing or manufacturing flexibleparts include mounting each flexible part in a jig having holder(s) thathold the flexible part in the desired shape and position so as, forexample, to replicate mounting of the flexible part to the other body.As used herein, when the flexible part is held or supported in aspecific and accurate manner to maintain a specific shape throughout,the flexible part is “constrained” by the jig or holder. As appreciatedby those skilled in the art, constraining the flexible part for andduring processing typically requires a unique jig constructed for eachflexible part to be processed. Furthermore, mounting of the flexiblepart on the jig can be time consuming and be prone to positional errors.

SUMMARY

This Summary and the Abstract herein are provided to introduce aselection of concepts in a simplified form that are further describedbelow in the Detailed Description. This Summary and Abstract are notintended to identify key features or essential features of the claimedsubject matter, nor are they intended to be used as an aid indetermining the scope of the claimed subject matter. The claimed subjectmatter is not limited to the implementations that solve any or alldisadvantages noted in the background.

A first aspect of the invention includes a system for processing aflexible part comprising a holder configured to hold the flexible partsecurely in an unconstrained position and an end effector configured toprocess the flexible part when held by the holder in the unconstrainedposition. At least one positioner is configured to support the holder orthe end effector for movement. A controller is configured to control thepositioner to provide relative movement between the end effector and theholder to process the flexible part, wherein movements of the positionerhave been compensated based on a comparison of a shape and/or positionof the flexible part in the unconstrained position with designspecifications of the part not in the unconstrained position.

A second aspect of the invention is a method for processing a flexiblepart comprising holding the flexible part securely in an unconstrainedposition; and controlling a positioner to process the flexible partbased on a comparison of a shape and/or position of the flexible part inthe unconstrained position with design specifications of the part not inthe unconstrained position.

One or more of the following features can be included in the system ormethod above in further embodiments thereof.

A storage device can be included having the design specifications storedon a computer readable medium of the storage device and accessed.

The shape and/or position of the flexible part in the unconstrainedposition can be ascertained and stored data on a computer readablemedium. Commonly, the shape and/or position is obtained using aprofilometer, such as a laser, camera system and/or measuring probe. Theshape and/or position data can be in the form of a plurality of scanframes, each portion corresponding to a different portion of theflexible part. The scan frames can comprise a geometric parameter withrespect to a coordinate system such as value(s) alone and/or withrespect to shape(s), for example, distances, such as distances betweenreference points; angles, such as angles represented by intersectingvectors or line segments; and/or a series of points or mathematicalexpression that define a geometric parameter(s) such as line segment,intersecting line segments, arcs, circles or other curved lines. Thescan frames are associated with different portions of the flexible partand each scan frame corresponds to a portion at a different positionwith respect to the flexible part such as along a reference direction.

A controller is configured to control the positioner and can includecontrolling the positioner based on a comparison of one or more scanframes with one or more reference frames, the reference framespreferably based on the design specification. Typically, controlling thepositioner includes determining a control path to move the positioner.

A spatial difference can exist between reference frames and scan frames.In other words, one or more reference frames will not coincide with thescan lines enough so that a comparison can be made. In such cases, aninterpolation must be made of to obtain one or more interpolatedreference frames and/or one or more interpolated scan frames. In suchembodiments, obtaining the comparison comprises obtaining aninterpolated reference frame for comparison with an existing scan frame,comparing an interpolated scan frame with an existing reference frame orcomparing an interpolated reference frame and with an interpolated scanframe. A unique matrix based on associated reference frames and scanframes where either can be interpolated as discussed above.

The system and method can be used for processing of the flexiblecomprises at least one of drilling, milling, trimming, scribing,chamfering or inspecting. It should be noted the positioner can becoupled to the end effector to control movement thereof or coupled tothe holder to control movement thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary part for processing.

FIG. 2 is a schematic diagram of a system for processing the part ofFIG. 1.

FIG. 3 is a visual representation of a virtual part defined by designspecifications.

FIG. 4 is a flow diagram illustrating a method for processing the part.

FIG. 5 is a schematic diagram pictorially illustrating processing of thepart.

FIG. 6 is a schematic diagram of a reference frame and scan frames.

FIG. 7 is a flow diagram illustrating inspecting a part.

FIG. 8 is a schematic illustration of a computing environment.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENT

An adaptive flexible part processing system and method are describedherein. Referring to FIG. 2, the system includes a jig or holder 102that holds the flexible part 10 in an “unconstrained” manner. As usedherein, “unconstrained” means that the flexible part 10 is not held in aspecific and accurate manner to maintain a specific shape throughout thebody of the flexible part 10, but rather held in a less exacting manner,where the shape can differ from design specifications, and typicallywhere the extent of difference from design specification can varythroughout the flexible part 10, typically without repeatability frompart to part although the parts are to be the same. “Designspecifications” as used herein refer to the shape, dimensions, etc. ofthe flexible part 10 as used in the manner for which it intended. It isdesired to process the flexible part 10 such that when used in themanner for which it intended, the flexible part 10 will change itsshape, for example, so as to be mounted to another part, or in otherwords it changes its shape to match the design specifications such thatit will properly mount to the other part.

It should be noted that the jig or holder 102 is shown schematicallysince the design will vary considerably depending on the part 10 to beformed or inspected. Many types of holders are known and can be usedwith the system and method herein described. Specific features of theholder 102 are not needed for purposes of understanding of the presentinvention other than that it holds the part 10 securely in any knownmanner, for example, via the use of clamps, fasteners, vacuum cups,magnets, fixed and/or adjustable support elements to name just a few.

FIG. 3 represents a view of the part 10′ meeting design specifications.The design specifications are often stored electronically in or oncomputer readable media. In other words, the design specifications ofthe part 10′ comprise desired dimensions of the actual part 10 and arerepresented herein by the illustration of FIG. 3, which could correspondto a computer aided design (CAD) file or the like, viewable on acomputer display or through the use of other rendering devices such asfrom a 2 or 3 dimensional printer, plotter, etc.

As a simple, non-limiting example suppose the design specifications ofthe flexible part 10′ requires recesses 17′ cut in each of the opposedflanges 14′ to be a selected distance 19 apart from each other whenfasteners are used to mount the actual flexible part 10 to another part.In addition, suppose that the design specifications require that thecenter section 12′ joins to the flange portions 14′ at a certain angle,as represented by double arrow 16, and that a certain angle is providedat which the flanges 14′ extend from the center section 12′ representedby double arrow 24. Since the location of the recesses 17 relative toeach other control at least in part the angles 16 on each side of theactual flexible part 10 when the flexible part 10 is mounted to theother part, the position of each of the recesses 17 must be accurate.However, as indicated above it is costly and time consuming to create aspecial jig or holder to hold the flexible part 10 in a constrainedposition matching the design specifications such that the spacingbetween the flanges 14 match the mounting of the flexible part 10 on theother part. Using this known processing technique, only after achievingthe proper constrained position of the flexible part 10 are the recesses17, for example, then made in each of the flanges 14.

In contrast, aspects of the present invention enable a flexible part 10to be processed accurately even though the flexible part 10 is beingheld in an unconstrained manner by holder 102 (i.e. held at least in aposition that does not match the design specifications as represented bypart 10′). In other words, unconstrained does not mean that the flexiblepart 10 is not held securely. To the contrary, an unconstrained flexiblepart 10 means the flexible part 10 is held in a manner to the extentnecessary for the type of processing being performed on the flexiblepart 10 to be done.

It should also be noted when the flexible part is held in anunconstrained manner, it does not mean that it is held within certaintolerances that allows work or other processes to be performed on theflexible part that without further regard to its shape on the jig orholder will yield an acceptable flexible part. As will be describedbelow, aspects of the system and method herein described allows aflexible part 10 to be held securely in an unconstrained manner, but anywork upon or inspection of the flexible part 10, is performed only aftertaking into account the shape of the flexible part 10 on the jig orholder as it is being held in the unconstrained manner; and inparticular, the variances present in the shape as it is being held dueto the flexibility of at least some portions of the flexible part 10.Only after the shape of the flexible part 10 as it is being held isknown, is the flexible part 10 processed where processing takes intoaccount the unconstrained shape of the flexible part 10. Using by way ofthe simple example referenced above, the formation of the recesses 17 inthe flanges 14, or inspection thereof, may be at a distance 21 from eachother that does not match the distance 19 of the recesses 17 when thepart is mounted to the other part. For example, the distance 21 betweenthe recesses 17 may be greater, narrower and/or out of alignment whenformed when the flexible part 10 is held by the holder in anunconstrained manner, but nevertheless when the flexible part 10 ismounted in the constrained position to the other part, the recesses 17are at the distance 19 from each other as required by the designspecifications such that the required angles 16 and 24 on each side ofthe flexible part 10 are obtained. It should be noted, the illustrationof FIG. 2 depicts the part 10 as being severely out of alignment withrespect to the design specifications for purposes of understanding.

The system also generally includes a controller 150 that controls apositioner 152 (typically movable in multiple degrees of freedom), wherethe positioner 152 commonly supports an end effector 154 for controlledmovement as needed to process the flexible part 10 as desired. Forexample, the end effector 154 can comprise device(s) to performdrilling, milling, trimming, chamfering, etc. on or inspection of theflexible part 10 as described in the background section above.

The controller 150 provides control signals to the positioner 152 suchthat the end effector 154 attached thereto moves about the flexible part10 typically according to a defined path 156 (herein also referred to asa “tool path”), a portion of which is illustrated. The controller 150,positioner 152 and end effector 154 attached to the positioner 152 arewell known devices. The controller 150 can comprise analog and/ordigital circuitry and is typically computer-based wherein a processorexecutes instructions stored therein so as to generate control signalsfor the positioner 152 and end effector 154. Likewise, the positioner152 can take numerous well known forms such as but not limited to amulti-degree of freedom robotic arm or a gantry system having the endeffector 154 mounted to a robotic arm or other support that is fixed ormoves relative to a bridge that in turn is moveable on one or morerails. In addition, a plurality of holders 102 can be used to hold alarger part 10 where each of the holders 102 hold a portion of the part10. A particular advantageous embodiment of a configurable system havinga plurality of multi-degree of freedom arms for holding a variety ofdifferent parts is described in U.S. patent application Ser. No.14/213,398, filed on Mar. 14, 2013 and entitled “MULTI-AXIS CONFIGURABLEFIXTURE”, which is incorporated herein by reference in its entirety.

It should be noted although it is common for the positioner 152 tosupport the end effector 154 for controlled movement thereof relative tothe flexible part 10 being held by the holder 102 held in a stationaryposition, in a further embodiment, a positioner 153 could be used tomove the holder 102 and thus the flexible part 10 relative to the endeffector 154 held in a stationary position. In yet another embodiment,separate positioners 152, 153 can be used to move both the end effector154 and the holder 102, respectively, if desired. Hereinafter, theembodiment where the holder 102 and flexible part 10 are held stationarywhile the positioner 152 supports and moves the end effector 154 will befurther described, nevertheless this should not be considered limiting,but rather aspects of the present invention can be applied to the otherembodiments described above as well.

Generally, the system and method herein described process the flexiblepart 10 with the desired end effector 154 mounted to the positioner 152,where the positioner 152 is controlled so as to account for theunconstrained manner in which the flexible part 10 is held by the holder102 in order to process the part 10 and obtain, or compare the actualpart 10 to the design specifications (represented by part 10′). As willbe described below, the system and method alter the actual tool path 156to take into account the unconstrained manner in which the part 10 isheld. In FIG. 3, tool path 156′ is a calculated or otherwise generatedor a known tool path that would be taken by the end effector 154 for apart 10′ to meet the design specifications when the part is ideallyheld. Since the part 10′ is a virtual part defined by the desired designspecifications, the tool path 156′ is not the actual tool path butrather a reference tool path that is used to obtain the actual tool path156.

FIG. 4 illustrates inputs or types of information needed and theprocessing to obtain the tool path 156 for processing the part 10 whenheld in an unconstrained manner. A first portion of informationcomprises the reference (nominal) tool path 156′ of the part 10′.Commonly, the reference tool path 156′ is derived based on the desired(nominal) design specifications, indicated at 202, which can be, forexample embodied in a CAD file or the like. Using the desired designspecifications 202, the reference tool path 156′ can be derived fromcomputer aided manufacturing programs or systems as indicated at 204.Commonly, the tool path 156′ is then processed to generate motioncontrol commands 206 in a form suitable to be used by or to control thepositioner 152. The reference tool path 156′ is illustrated in FIG. 5where the part 10′ again is illustrative of the design specifications.

A second type of information needed for obtaining the tool path 156 arereference frames based on the nominal design specifications of the part10′. As used herein a “frame” is a portion of the part 10′ or part 10that is used as the basis of comparison between the part 10′ as definedby the design specifications with the same portion found in the part 10.The frame can be any geometric parameter that is used to define aportion of the part 10′ and part 10. Such parameters include but are notlimited to value(s) by themselves and/or with respect to shape(s), forexample, distances, such as distances between reference points; angles,such as angles represented by intersecting vectors; and/or a series ofpoints or mathematical expression that define a geometric parameter(s)such as line segment, intersecting line segments, arcs, circles, etc. Inone advantageous embodiment, the frame comprises geometric parameter(s)related to a cross-section of the part 10′ or 10 along a referenceddirection.

Referring to FIG. 5, the reference frames 208 comprise line segments210, joined together at one end on each side of the part 10′ (hereinillustrated on one side by way of example) that represent the centersection 12′ joined to each of the opposed flanges 14′. As such, theframes are also indicative of the angles 16 and 24 of the respectiveportion of the part 10′. The fact that the frames 208 comprise joinedline segments should not be considered limiting in that if desired theline segments or other geometric parameters can be unconnected butotherwise associated with each other. In one embodiment, each framecomprises pairs of connected line segments on each side of the centersection 12′ as illustrated in FIG. 3. Taken along a reference directionof the part 10′, such as a longitudinal axis, the plurality of referenceframes 208 define the part 10′. The plurality of reference frames 208can be generated or derived (e.g. calculated) based on the designspecifications embodied for example in the CAD file using CAD macroprogramming 212 or similar processing of the design specifications 202.Typically, the plurality of reference frames 208 comprise spaced apartindividual frames along the reference direction of the part 10′. Thespacing between adjacent frames can be selected based on the accuracydesired and/or the flexibility of the actual part 10.

A third type of information needed for obtaining the tool path 156 areframes based on the unconstrained part 10 being held. As used herein theframes 220 based on the unconstrained the part 10 are referred to as“scan frames”. A plurality of scan frames 220 are best illustrated inFIG. 2. In FIG. 5 only the plurality of scan frames 220 are shown sincethe part 10′ is illustrated rather than the actual unconstrained part10. Typically, the scan frames 220 do not depart as significantly fromthe reference frames 208 as that illustrated in FIG. 5, which is done sofor purposes of understanding.

Referring to FIG. 4, the scan frames 220 are obtained from measured dataof the unconstrained part 10. Typical measurement devices includeprofilometers such as but not limited to probes, offset lasers, camerasor the like.

In many instances of processing a part, the reference frame(s) will notcoincide with an actual scan frame as measured directly from theprofilometer with the desired accuracy or correspondence. In oneembodiment, it is advantageous to obtain scan frame data at a higherresolution in the same reference direction than that of the spacing ofthe reference frames 208. The higher resolution scan data allows aninterpolated scan frame to be obtained, which can then be associatedwith the corresponding reference frame. In FIG. 5, individual referenceframes of the plurality of reference frames 208 are each illustratedwith a corresponding scan frame (actual or interpolated) of theplurality of scan frames 220. Processing corresponding to associatingscan frames 220 with reference frames 208 in order to ascertain ifinterpolation is needed is indicated by double arrow 221 in FIG. 4.

Referring to FIG. 6, a portion of a reference frame 208A associated withone side of the part 10′ (not shown in FIG. 6) is illustrated with aseries of portions of scan frames 220A, 220B, 220C and 220D. Asillustrated, the reference frame 208A does not coincide with either ofthe scan frames 220B and 220C, but rather is disposed between them. Inorder to obtain a scan frame with the desired accuracy of associationwith the reference frame 208A (which will be used later), a scan framecoinciding with the reference frame 208A can be obtained through knowninterpolation calculations of the data associated with scan frames 220Band 220C. It should be noted either an interpolated scan frame can beobtained so as to be compared with an existing reference frame, or aninterpolated reference frame can be obtained so as to be compared withan existing scan frame, or both an interpolated reference frame and aninterpolated scan frame can be obtained so as to be compared with eachother.

At this point it should be noted that there is commonly registrationexisting between the design specifications (represented by 10′) and part10. For example, the part 10 to be processed can include one or moreregistration elements (markings or characteristic physical portions suchas a known point on the part), for example, as illustrated in FIG. 2 at240, while the design specifications include a similar registrationelement(s) 240′. Using a comparison of the registration element(s) 240of the part 10 with the registration element(s) 240′ of the designspecifications 10′, the scan frames 220B and 220C where the referenceframe 208 would be disposed can be ascertained, because the series ofscan frames 220 are obtained at known intervals. It should be noted thatthe registration elements 240 illustrated in FIG. 2 are onlyillustrative in that the registration element can take many forms.Generally, the registration element(s) 240 need only be quality and/orquantity to provide the requisite information so as to understand thedifferences between the unconstrained actual part 10 relative to thedesign part 10′ to enable the interpolation calculations for any and allinterpolated scan lines to be accurate.

Referring back to FIG. 4, a transform matrix with respect to a suitablecoordinate system (Cartesian, Polar, etc.) can be obtained for each pairof associated reference and scan frames of part 10. Each transformmatrix represents the spatial difference between each associatedreference and scan frame, and thus the spatial difference of thecorresponding portion of part 10 with respect to the same portion of thedesign specifications represented by part 10′. By applying each uniquetransform matrix to appropriate motion commands 206, the motion commands206 for the reference tool path 156′ are spatially adjusted so as toprovide motion control commands 250 that correspond to that of tool path156, which when the end effector 154 is applied to the unconstrainedpart 10, will yield or correspond to an actual part meeting the designspecifications for any of the exemplary adaptive manufacturing processesindicated at 252. Although illustrated in FIG. 4 where the uniquetransform matrices are applied to the motion commands 206, it should beunderstood that the unique transform matrices can be applied to thereference tool path 156′, whereupon the tool path 156 for theunconstrained part 10 is then obtained. The motion commands for thepositioner 152 can then be obtained from the tool path 156.

FIG. 7 illustrates an example of application of the foregoing to partinspection in detail. For each actual part 10 to be inspected,inspection points and Dimensional Measuring Interface Standard (DMIS)requirements 300 of nominal design specifications of a part, areprovided to Dimensional Measuring Interface Standard software 302. Thenominal inspection locations and the reference frames corresponding tothe design specifications of the part, as discussed above, are providedto a machine controller 304. In the manner discussed above, scan framesfor the part 10 to be inspected are obtained and associated withcorresponding reference frames so as to obtain a plurality of uniquetransform matrices that in turn are used to transform the nominalinspection locations so that they can be compared with correspondingmeasured inspection locations as should be found on the unconstrainedpart 10. The measured inspection locations are then compared tocalculated measured inspection locations so to realize a unique“Inverse” transformation matrix, which is returned with the measurementresults to the Dimensional Measuring Interface Standard software 302.Using the foregoing information, DMIS issues an inspection report 306for the actual part.

The processing described above can be performed on controller 150 or ona separate computing device remote from or connected to controller 150.Likewise, portions of the processing can be performed on differentcomputing devices connected or unconnected to each other. Generally, thecomputing environment for the controller 150, positioner 152 or theother computing devices mentioned above can be implemented on a digitaland/or analog computer. Although not required, portions of thecontroller 150, positioner 152 or the other computing devices mentionedabove can be implemented at least in part, in the general context ofcomputer-executable instructions, such as program modules, beingexecuted by a computer 470 illustrated in FIG. 8. Generally, programmodules include routine programs, objects, components, data structures,etc., which perform particular tasks or implement particular abstractdata types. Those skilled in the art can implement the descriptionherein as computer-executable instructions storable on a computerreadable medium. Moreover, those skilled in the art will appreciate thatthe invention may be practiced with other computer systemconfigurations, including multi-processor systems, networked personalcomputers, mini computers, main frame computers, and the like. Aspectsof the invention may also be practiced in distributed computingenvironments where tasks are performed by remote processing devices thatare linked through a communications network. In a distributed computerenvironment, program modules may be located in both local and remotememory storage devices.

The computer 470 comprises a conventional computer having a centralprocessing unit (CPU) 472, memory 474 and a system bus 476, whichcouples various system components, including memory 474 to the CPU 472.The system bus 476 may be any of several types of bus structuresincluding a memory bus or a memory controller, a peripheral bus, and alocal bus using any of a variety of bus architectures. The memory 474includes read only memory (ROM) and random access memory (RAM). A basicinput/output (BIOS) containing the basic routine that helps to transferinformation between elements within the computer 470, such as duringstart-up, is stored in ROM. Storage devices 478, such as a hard disk, afloppy disk drive, an optical disk drive, etc., are coupled to thesystem bus 476 and are used for storage of programs and data. It shouldbe appreciated by those skilled in the art that other types of computerreadable media that are accessible by a computer, such as magneticcassettes, flash memory cards, digital video disks, random accessmemories, read only memories, and the like, may also be used as storagedevices. Commonly, programs are loaded into memory 474 from at least oneof the storage devices 478 with or without accompanying data.

Input devices such as a keyboard 480 and/or pointing device (mouse) 44,or the like, allow the user to provide commands to the computer 470. Amonitor 484 or other type of output device is further connected to thesystem bus 476 via a suitable interface and provides feedback to theuser. If the monitor 484 is a touch screen, the pointing device 82 canbe incorporated therewith. The monitor 484 and typically an inputpointing device 482 such as mouse together with corresponding softwaredrivers form a graphical user interface (GUI) 486 for computer 470.Interfaces 488 on each of the controller 150, positioner 152 or othercomputing devices mentioned above allow communication between controller150, positioner 152 and/or other computing devices mentioned above.Commonly, such circuitry comprises digital-to-analog (D/A) andanalog-to-digital (A/D) converters as is well known in the art.Functions of controller 150 and/or positioner 152 can be combined intoone computer system. In another computing environment, each of thecontroller 150 and/or positioner 152 is a single board computer operableon a network bus of another computer, such as a supervisory computer.The schematic diagram of FIG. 8 is intended to generally represent theseand other suitable computing environments.

Although the subject matter has been described in language directed tospecific environments, structural features and/or methodological acts,it is to be understood that the subject matter defined in the appendedclaims is not limited to the environments, specific features or actsdescribed above as has been held by the courts. Rather, theenvironments, specific features and acts described above are disclosedas example forms of implementing the claims.

What is claimed is:
 1. A method for processing a flexible partcomprising: holding the flexible part in a secured unconstrainedprocessing position; accessing a storage device having specifications ofthe flexible part not in the secured unconstrained processing positionstored on a computer readable medium of the storage device; andcontrolling a positioner to process the flexible part while in thesecured unconstrained processing position by comparing a difference inshape due to a flexibility of the flexible part in the securedunconstrained processing position with a shape of the flexible part notin the secured unconstrained processing position when the flexible parthas a different shape.
 2. The method of claim 1 and further comprising:obtaining the difference in shape to the flexibility of the flexiblepart in the secured unconstrained processing position; and storing dataindicative of the difference in shape in memory accessible to acomputing device.
 3. The method of claim 2 wherein the obtaining of thedifference in shape includes using a profilometer, such as a laser,camera system and/or measuring probe.
 4. The method of claim 2 whereinthe obtaining of the difference in shape includes obtaining a pluralityof scan frames, each scan frame corresponding to a different portion ofthe flexible part.
 5. The method of claim 4 wherein the plurality ofscan frames comprise a geometric parameter with respect to a coordinatesystem for at least one of a distance, an angle, an arc and a circle. 6.The method of claim 4 wherein each scan frame of the plurality of scanframes corresponds to a portion at a different position with respect tothe flexible part along a reference direction.
 7. The method of claim 4wherein the controlling the positioner includes controlling thepositioner based on a comparison of one or more scan frames of theplurality of scan frames with one or more corresponding reference framesfor one or more respective portions of the flexible part.
 8. The methodof claim 7 wherein comparing the difference in shape comprises obtainingat least one of an interpolated reference frame and an interpolated scanframe.
 9. The method of claim 8 wherein the comparing the difference inshape comprises one or more of comparing the interpolated referenceframe with an existing scan frame, comparing the interpolated scan framewith an existing reference frame or comparing the interpolated referenceframe with the interpolated scan frame.
 10. The method of claim 7wherein the controlling the positioner includes a control path to movethe positioner.
 11. The method of claim 10 wherein a spatial differenceexists between each associated reference frame and scan frame fordifferent portions of the flexible part.
 12. The method of claim 11 andfurther comprising forming a unique matrix based on associated referenceframes and corresponding scan frames.
 13. The method of claim 1 whereinthe processing comprises at least one of drilling, milling, trimming,scribing, chamfering and inspecting.
 14. The method of claim 1 whereinthe positioner is coupled to an end effector to control movementthereof.
 15. The method of claim 1 wherein the positioner is coupled toa holder to control movement thereof.
 16. A method for processing aflexible part with a computer controlled positioner having an endeffector, the method comprising: holding the flexible part in a securedunconstrained processing position; accessing a storage device to obtaininformation of the flexible part in a shape that is different than thesecured unconstrained processing position; and processing the flexiblepart with the end effector in the secured unconstrained processingposition by controlling the positioner and the end effector based on acomparison of a difference in shape due to a flexibility of the flexiblepart in the secured unconstrained processing position with theinformation of the flexible part.
 17. The method of claim 16 whereinprocessing comprises at least one of drilling, milling, trimming,scribing, chamfering and inspecting.
 18. The method of claim 16, whereinprocessing is performed only after the difference in shape due to theflexibility of the flexible part in the secured unconstrained processingposition is known.
 19. The method of claim 16, wherein the informationcomprises design specifications of the flexible part, the method furthercomprising: obtaining the difference in shape due to the flexibility ofthe flexible part in the secured unconstrained processing position; andstoring data indicative of the difference in shape in memory accessibleto a computing device.
 20. The method of claim 19 wherein the obtainingof the difference in shape due to the flexibility of the flexible partin the secured unconstrained processing position includes obtaining aplurality of scan frames, each scan frame corresponding to a differentportion of the flexible part.
 21. The method of claim 20 wherein theplurality of scan frames comprise one or more geometric parameters withrespect to a coordinate system for at least one of a distance, an angle,an arc and a circle.
 22. The method of claim 20 wherein each scan frameof the plurality of scan frames corresponds to a portion at a differentposition with respect to the flexible part along a reference direction.23. The method of claim 20 and wherein the controlling the positionerincludes controlling the positioner based on a comparison of one or morescan frames of the plurality of scan frames with one or more referenceframes based on the design specifications.